Bahir Dar University

Ethiopian Institute of Textile and Fashion Technology

(EiTEX)
Course Title: Computer Integrated Manufacturing
(FTec6041)

Review: Automated Guided Vehicle for material handling system in garment industry

Prepared by: Zerihun Kebede

Submitted To: Dr. Mulat Alubel. (PhD.)

Submission date: April 2021

Bahir Dar
Ethiopia
Abstract

Material Handling is an important activity within the larger system by which material is moved,
stored, and tracked in apparel manufacturing industry. The term commonly used for larger systems
is logistics, which is concerned with the acquisition, movement, storage, and distribution of
materials and products, as well as the planning and control of these operations. Automated guided
vehicles are uniquely designed to automate tasks for which humans are not necessary. They
automate long walks in warehouses, set the pace for workers, and eliminate the physical rigors of
a traditionally physically demanding job. It is a flexible, scalable and cost-effective solution for
warehouses and distribution centers offering innovative technology designed to tackle some of
warehousing’s biggest challenges. Sometimes called self-guided vehicles or autonomous guided
vehicles, automated guided vehicles (AGVs) are material handling systems or load carriers that
travel autonomously throughout a warehouse, distribution center, or manufacturing facility,
without an onboard operator or driver. The most common application of such system is to move
materials around a manufacturing facility or warehouse.

Keywords; Apparel, Automated guided vehicles, Material handling,

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Contents
1. Introductions ....................................................................................................................................... 4
1.1 Literature Review ................................................................................................................................. 5
2. Applications of AGVs in garment industry ...................................................................................... 6
3. Types Automated Guided Vehicles ................................................................................................... 6
3.1. Fork lift ........................................................................................................................................ 6
3.2. Load Transfer AGV .................................................................................................................... 7
3.3. Clamp AGV ................................................................................................................................. 7
3.4. Productive Tugger Automated Guided Vehicle ....................................................................... 7
3.5. Autonomous Mobile Robots ....................................................................................................... 7
4. Components of an AGV...................................................................................................................... 7
5. Guidance Systems for AGVs .............................................................................................................. 8
6. Types of Control System for AGVs ................................................................................................... 8
7. Interface of AGVs with Other Systems ............................................................................................. 8
Conclusion ................................................................................................................................................... 9
References .................................................................................................................................................. 10

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1. Introductions
An Automated guided vehicle is a material handling system that uses independently operated, self-
propelled vehicle which is guided along defined route in the facility through markers, wires,
magnets, lasers or nowadays virtual programming for navigation with on board batteries for easy
and durable operation. The most common application of AGV is to move materials around a
manufacturing facility or warehouse. The AGV can tow or lift the objects to move raw materials
or finished products.

Automated material handling system improves accuracy and efficiency of transportation, storage
and retrieval of materials. Examples are computerized conveyors and Automatic storage and
retrieval systems (ASRS) in which computers give direction to automatic loaders to pick and place
items. Benefits of this system include quicker material movement, lower inventories, and lower
storage spaces, reduces product damage and reduces labor cost. A material handling system can
be simply defined as an integrated system involving activities such as handling and controlling of
materials. Materials include all kind of raw materials, work in progress (wip), sub-assemblies, and
finished assemblies.

Automated guided vehicles (AGVs), commonly known as driverless vehicle are turning out to be
an important part of the automated manufacturing system. With the shift from mass production to
mid-volume and mid-variety, all flexible manufacturing systems uses AGVs. Now a days
industries require not only machine flexibilities but also material handling, storage and retrieval
flexibilities. Hence the importance of an AGV has grown in manifold. AGVs are battery-powered
driverless vehicles with programming capabilities for destination, path selection and positioning.
AGVs belongs to a class of highly flexible, intelligent and versatile material handling systems used
to transport material from various loading locations to various unloading locations throughout the
facility. The capability related to collision avoidance is nicely inbuilt in AGV.

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1.1 Literature Review
[1] Have presented a bi-directional path flow layout and a routing algorithm that guarantee
conflict-free, shortest-time routes for AGVs. Automatic Guided Vehicles (AGVs) was a modified
towing tractor that was used to pull a trailer and follow an overhead wire in a warehouse. [2] Have
addressed operational control factors such as demand selection and assignment, route planning and
traffic management, idle AGV positioning and AGV characteristics. By the late 1950's and early
1960's, towing AGVs were in operation in many types of factories and warehouses [3]. [4] Have
compared and discussed unidirectional and bi-directional guide paths for vehicle routing. They
have also presented a model of a bi-directional traffic flow guide-path. [5] Have developed an
analytical model using a regression technique to estimate the number of vehicles required by a
facility a manufacturing industries. [6] have developed omnidirectional Automated Guided
Vehicle (AGV) with a novel omnidirectional wheel named MY3 wheels who have special structure
and material due to that, the AGV has full three DOFs. [7] Have discussed key issues to be
considered for design and control of automated guided vehicles such as guide path design,
estimating number of vehicles, vehicle scheduling, vehicle routing, idle vehicle management and
conflict resolution. They have also discussed and classify important models. [8] Have developed
an Automated Guided Vehicle in which customized material handling tasks can be performed
using PLC a manufacturing industries.

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2. Applications of AGVs in garment industry
Automated guided vehicle systems are used for tasks that would typically be handled by forklifts,
conveyor systems or manual carts, moving large volumes of material in a repetitive manner

AGVs are used in a variety of applications. They’re often used for transporting raw materials such
as fabric, trim and accessories, For example, AGVs can transport raw materials from receiving to
the warehouse or deliver materials directly to production lines. AGVs consistently and reliably
deliver raw materials needed without human intervention, ensuring that production lines always
have the materials they need without interruption.

In addition to transporting raw materials, AGVs are used in work-in-process applications and with
finished goods to support production or manufacturing lines. In work-in-process applications,
AGVs move materials or parts from the warehouse to production lines or from one workstation to
another, providing repetitive and efficient movement of materials throughout the manufacturing
process.

AGVs are also used in inbound and outbound handling for replenishment and for picking. For
example, AGVs may be used to transport inventory from receiving to storage locations or
from long-term storage locations to forward picking locations to replenish stock. Moving
inventory from long-term storage to forward picking locations ensures that adequate inventory is
accessible to pickers, making the order picking process more efficient. AGVs such as collaborative
mobile robots assist in the picking process by guiding warehouse associates through tasks and
transporting picked orders to packaging and shipping workstations.

3. Types Automated Guided Vehicles

There are different types of automated guided vehicles that are able to provide different service
requirements. These are:
3.1. Fork lift
It has a capability to pick up and drop off palletized loads automatically from floor level and put
to prescribed destination. It has capability to position its forks at any height so that conveyers or
load stands with different heights in material handling system can be serviced. These kind of AGVs

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are expensive, therefore they are used in the case of full automation. The truck is accoutered with
sensors at the fork end so that it can be handle high level stacking on its own. These systems have
advantage of greater flexibility in integrating with other subsystems with various loading and
unloading heights throughout the material handling system.

3.2. Load Transfer AGV

They are applied in handling small, light parts over moderate distance and distribute the parts
between storage and number of work stations.
3.3. Clamp AGV

It is termed as pallet trucks, which is designed to work and transport cylindrical loads. Normally
such kind of AGVs can be used in Textile, and garment industries for loading and unloading of
material.

3.4. Productive Tugger Automated Guided Vehicle

It is used to pull non-driven carts that are charged with loads. They can pull either manually or
automatically with an actuated hitch. These AGVs are more productive and capable of carrying
more goods compare to all other AGVs. Hence there is a considerable increase in capacity and
efficiency.

3.5. Autonomous Mobile Robots

(AMRs) are typically more technologically advanced than other types of AGVs. While many
AGVs use fixed navigation systems, such as wires or magnetic tape, many AMRs are equipped
with intelligent navigation capabilities such as sensors and camera systems that enable them to
detect and navigate around obstacles. Thanks to more sophisticated technology, AMRs can
dynamically navigate a warehouse or other facility and plan the most efficient paths.

4. Components of an AGV
There are basic four components of an automated guided vehicle. These include:

I. Vehicle which is used to move the material within the system.

II. Guide Path which will guide the vehicle to move.
III. Control Unit which monitors and directs system and

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IV. Computer Interface which is connected with other computers and systems to control and
monitor overall function of an AGV.

5. Guidance Systems for AGVs

The main purpose of a guidance system is to keep the vehicle in the predetermined path. The main
advantage of AGVs is that the guide path can be changed easily at low cost compared to the high
cost of modifying fixed-path equipment such as conveyors, chains and towlines. Some of the
familiar guidance systems are wire guidance system, optical guidance system, inertial guidance
system, infrared guidance system, laser guidance system, and teaching type guidance system.

6. Types of Control System for AGVs

There are basic three types of control system for AGVs:

I. Computer Controlled System in which vehicle movement is controlled and monitored by

the system controller.
II. Remote Dispatch Control System in which a human operator controls the movement of
AGV through a remote control station. and
III. Manual Control System in in which the operator loads the vehicle and enters a destination
into on-board control panel of the vehicle.

7. Interface of AGVs with Other Systems

The computer controlled system can link the AGVs with other Systems/Subsystems in the facility.
They are:

(a) Automatic Storage and Retrieval Systems

(b) Computer Numerical Controlled (CNC) Machines
(c) Shop Floor Control System
(d) Process Control Equipment and
(e) Flexible Manufacturing Systems (FMS)

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Conclusion
Automatic Guided Vehicle can be used in a wide variety of applications to transport many different
types of material including pallets, fabric rolls, racks, carts and containers. The important
advantages of AGVs are reduce manpower, increase productivity, eliminate, reduce product
damages, better control of material management, speed of delivery, flexibility of path, and
reduction in labor cost. There are also some disadvantages of AGVs like, Installation cost is very
high, AGVs are fragile and should be handled with care, regular inspection and maintenance
needed, it should be recharged periodically and it will stop delivery when it is forced off the path.
Despite of these disadvantages they are widely used in manufacturing for the movement of
material from one department to another, making the garment manufacturing processes smooth
and efficient.

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References
[1] B. R. Sarker and S. S. Gurav, “Route planning for automated guided vehicles in a
manufacturing facility”, International Journal of Production Research, Vol. 43, pp. 46594683,
2005.
[2] Christopher Oboth, Rajan Batta and Mark Karwan, “Dynamic conflict-free routing of
automated guided vehicles”, International Journal of Production Research, Vol. 37, pp. 2003-2030,
2010.
[3] Khosro Bijanrostami, “Design and Development of an Automated Guided Vehicle for
Educational Purposes”, Master of Science Thesis, Institute of Graduate Studies and Research,
Eastern Mediterranean University, Gazimağusa, North Cyprus, 2011.
Material Handling System Based on Automated Guided
Vehicle: Scope, Limitation and Application” February 2017.
[5] Robert Arifin and Pius J. Egbelu, “Determination of vehicle requirements in automated guided
vehicle systems: A statistical approach”, Production Planning & Control, Vol. 11, pp. 258 – 270,
2010.
[6] Suyang Yu, Changlong Ye, Hongjun Liu and Jun Chen, “Development of an omnidirectional
Automated Guided Vehicle with MY3 wheels”, Perspectives in Science, Vol. 7, pp. 364-368,
2016.
[7] Tuan Le-Anh, M.B.M. and De Koster, “A Review of Design and Control of Automated Guided
Vehicle Systems”, European Journal of Operational Research, Volume 171, pp. 123, 2006.
[8] V. Jaiganesh, J. Dhileep Kumar and J. Girijadevi, “Automated Guided Vehicle with Robotic
Logistics System”, Procedia Engineering, Vol. 97, pp. 2011-2021, 2014.

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